Banks Power Exhaust System Installation Instruction

Banks Power Exhaust System Installation Instruction
Owner’s Manual
with Installation Instructions
Banks Monster
Exhaust System
®
2006-2007 Dodge Ram 1500 HEMI Mega Cab
2006-2008 Dodge Ram 1500 HEMI RCSB, CCSB, CCLB
THIS MANUAL IS FOR USE WITH MONSTER EXHAUST SYSTEMS 48576, 48578,
48579
General Installation Practices
1. Before starting work, familiarize
yourself with the installation procedure
by reading all of the instructions.
2. The exploded view (Figure 1) provides only general guidance. Refer
to each step and section diagram in
this manual for proper instruction.
3. Throughout this manual, the
left side of the vehicle refers to the driver’s side, and the right side to the
passenger’s side.
4. Disconnect the negative (ground)
cable from the battery (or batteries, if
there are two) before beginning work.
5. Route and tie wires and hoses a
minimum of 6” away from exhaust
heat, moving parts and sharp
edges. Clearance of 8” or more is
recommended where possible.
6. When raising the vehicle, support
it on properly weight-rated safety
stands, ramps or a commercial hoist.
Follow the manufacturer’s safety
precautions. Take care to balance the
vehicle to prevent it from slipping or
falling. When using ramps, be sure the
front wheels are centered squarely on
the topsides. When raising the front
of the vehicle, put the transmission in
park, set the parking brake, and block
the rear wheels. When raising the back
of the vehicle, be sure the vehicle is
on level ground and the front wheels
are blocked securely.
Caution! Do not use floor jacks to
support the vehicle while working
under it. Do not raise the vehicle
onto concrete blocks, masonry
or any other item not intended
specifically for this use.
7. During installation, keep the work
area clean. Do not allow anything to
be dropped into intake, exhaust, or
lubrication system components while
performing the installation, as foreign
objects will cause immediate engine
damage upon start-up.
Tools Required:
• 1⁄ 2” and 3⁄ 8” drive ratchets with
standard and metric sockets and 1⁄ 2”
and 3⁄ 8” drive extension
• Standard and metric combination or
open-end wrenches
• Standard screwdriver
• Clean shop towels or rags
• Pry-bar Highly recommended tools
and supplies:
• Foot-pound torque wrench
• Penetrating oil or light lubricant
spray
2
97054 v.4.0
Monster Exhaust System Installation
1. Disconnect the negative (ground)
cable from the battery (if there is more
than one battery, disconnect both
negative cables). Secure the cable so
it cannot accidentally come in contact
with the post.
2. Raise the vehicle and support it
securely with properly weight-rated
safety stands, ramps or a commercial
hoist. Take care to balance the vehicle
to prevent it from slipping or falling.
When using ramps, be sure the wheels
are centered squarely on the topsides.
Place the transmission in park
(automatic), set the parking brake and
securely block the wheels that are on
the ground.
CAUTION: DO NOT WORK UNDER
ANY VEHICLE SUPPORTED ONLY
BY A JACK. SEVERE INJURY MAY
RESULT.
3. From under the vehicle remove the
factory exhaust starting at the rear
of the muffler. Remove the tailpipe
by removing the factory band clamp
on the muffler to tailpipe connection.
Remove the factory tailpipe hanger
pin (attached to resonator) from the
rubber grommet and remove the
tailpipe from the vehicle.
NOTE: Spray lubricant may assist in
hanger pin removal. Rubber hangers
can also be removed from the vehicle
to assist in tailpipe / muffler removal.
4. Loosen the factory band clamp at
the front of the muffler. Remove the
front and dual rear muffler hanger pins
from the rubber hangers. Remove the
muffler from the vehicle. The factory
resonator pipe will remain on the
vehicle.
5. Install the 3” single pin hanger
clamp onto the inlet of the Banks
intermediate pipe. Insert the hanger
pin into the vehicle’s rubber hanger.
Install the Banks intermediate pipe
onto the factory resonator. Orient the
intermediate pipe as shown in Figure 2.
NOTE: Once the pipe / muffler has
been completely engaged in the slip
joint, mark the pipe with a scribe or
tape for reference when tightening the
clamps later in the installation. Mark
each slip joint in this fashion.
6. Install a 3” saddle clamp onto the
intermediate pipe outlet. Install the
Monster Muffler inlet (Note the inlet
labeling of the muffler). Orient the
Monster logo such that it is visible
from the passenger side and parallel
with the frame rail. Align the clamp
onto the muffler outlet (see Figure 2).
NOTE: All clamps should be positioned
at the beginning of the slots (on the 1⁄ 2
circle punch) and evenly tightened.
7. Install the 3” dual hanger clamp
onto the Banks Muffler outlet such that
the hanger pins are facing forward.
Install the two (2) clamp hanger pins
into the corresponding muffler rubber
grommet (see Figure 3).
8. From the vehicle rear, route the
tailpipe over the rear end. Start
the tailpipe hanger pin into the
corresponding vehicle rubber hanger.
Install the tailpipe into the Banks
Muffler outlet. Lightly tighten the rear
muffler hanger clamp to secure the
tailpipe (see Figure 3).
9. Adjust the tip about 1⁄ 2” under the
body panel, such that the tip position
is aesthetically pleasing (See Figure 3).
10. With the exhaust positioned
properly, begin to tighten the clamps
starting with the ones closest to the
front of the vehicle and working your
way back. Torque the exhaust clamps
evenly to 35 ft-lbs. Make sure that
each slip is fully inserted (+/- 1⁄ 4”).
97054 v.4.0
3
General Assembly Diagram
Figure 1
4
97054 v.4.0
RCSB, CCSB,
CCLB
Item #
Description
Mega
Cab
20062007
2008
20062007
P/N
P/N
P/N
Qty
-
-
-
1
1
Factory Resonator Pipe (Not Supplied)
2
Front Muffler Hanger Clamp
53230
53230
53233
1
3
Intermediate Pipe
53225
53225
53225
1
4
Exhaust Clamp, 3” HD
52465
52465
52465
1
5
Monster Muffler
54005
54005
54005
1
6
Rear Muffler Hanger Clamp
53232
53232
53234
1
7
Tailpipe, w/weld on Tip
53231
53236
53235
1
8
Banks Urocals
96009
96009
96009
2
97054 v.4.0
5
Figure 2
MONSTER
LOGO
ORIENTATION
REAR HANGER
CLAMP
MONSTER
MUFFLER
INLET
INTERM
PIPE
FACTORY
RESONATOR
6
97054 v.4.0
3“ CLAMP
FRONT
HANGER
CLAMP
Figure 3
11. Remove the protective covering
from the tailpipe tip.
Caution: the protective covering
may ignite and burn if not removed
prior to running the engine.
12. Your system includes two (2)
Banks Power logos designed to
complement the Dodge HEMI emblems
on the vehicles front fenders.
BANKS POWER PERFORMANCE EXHAUST
13. Re-connect the negative battery
cable. Start the engine and listen for
exhaust leaks. Tighten the exhaust
clamps as necessary. Whenever
possible, tack weld slip connections
to prevent disengagement is
recommended.
The Banks Monster Exhaust installation
is now complete.
EXHAUST SYSTEMS
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